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Well my host finally came today and it was a lot smaller than I expected! Anyway, came in good condition, no scratches and paint/ano looks great. THe lens and reflector is plastic, but the entire body is aluminum. The switch in the tail loose when I got it and as a result did not work, so that took a bit of tinkering to fix but now it works great. I never saw how bright the orginal LED was beacuse I fried it on a 9v battery *:-[ (dont ask). So anyway, im tearing it apart right now.
With LAva Drive, AA Li-Ion and Dollar for size
Battery fits nicely in the first and second section
Leaving the entire last section( less once screwed in and with battery contact ine. Its about .98 inches) for driver, module, and heat sinking
Tried to get a shot of inside of the head
THeres a lip at the far end

So, my first problem is how to get the battery contact to stick on the end of the second section as so...
Heres shot of the inside
I dont know how to get it to stick without cutting off the negative connection to the body. Are there any conductive glues? Maybe just try two small drops of super glue? Or should I try and mount it on the inside of the head(third section)?

how are you going to secure the aixiz module in the head? machine a ring to fit?
that battery contact board, does it fit inside the head section? if it doesn't then when you screw the head on, it should get wedged up against the body, no glue required. otherwise if you have the body of the laser in contact with the case, it doesn't matter if the battery contact is touching the case, because the circuit will be grounded through the laser body. so you can just glue it and only use that board for the positive connection.

i have one of these flashlights on the way from DX, it looks like a decent body.

Thanks. Ill just glue it to the body and make the connection somehwere else.
Next question, where do you guys get your aluminum parts to make heatsinks? I went to home depot, they had practically nothing, so I got something that was stainless steel. Just did a little research and foudnt hat the thermal conductivity of aluminum is ridiculously higher than steel, so I wont be using that. Is lowes any better, or will I have to find a hardware store?

Thanks. Ill just glue it to the body and make the connection somehwere else.
Next question, where do you guys get your aluminum parts to make heatsinks? I went to home depot, they had practically nothing, so I got something that was stainless steel. Just did a little research and foudnt hat the thermal conductivity of aluminum is ridiculously higher than steel, so I wont be using that. Is lowes any better, or will I have to find a hardware store?